Al Tasnim Enterprises LLC

Plant,Equipment & Logistics Division

Detailed Failure Analysis (DFA)
Region & Cluster : Maintenance Plant Description :
Equipment Code : Year of Manufacture :
Equipment Description : Total HMR / KMR Run :
Eqpt Make & Model : Equipment Status : Working / Breakdown
Sl.No Check Point Observation Parameter
(I) Engine Make & Model : Sl.No :
1 Exhause Smoke Normal - Blue Grey - Block - White
2 Noise Normal - Knocking Sound - Heavy Sound
3 RPM Low Idle : High Idle :
i) Lubrication System
Low Idle - High Idle -
1 Oil Pressure
Kg/cm2
2 Oil level Measure Drain Qty - Grade of oil Qty in Litrs :
3 High Oil Consumption Measure Top up Qty in between schedule services Qty in Litrs :

4 Fuel Mixing in coolant
5 Fuel Mixing in Engine oil
6 Coolant Mixing in Engine oil
7 Leakages
8 Blowby
9 Breather Condition
Injector sleeve/o-ring failure Check for Coolant Top Up History from
Optr & Driver
Carry out MORSE TEST to find the faulty injector
Check Radiator Pressure Cap Rating -
Water pump seal - Radiator Pressure Cap - Gasket puncture - Cylinder liner puncture - KPA/Kgcm2
Head Gasket -Tappet cover - Crank case - Timing cover (Front - Rear) - i) Seeepage ii) Leak -Light - Medium -
Crank shaft seal (Front -Rear) Heavy
Low - medium - excess
Clean - Clogged - Missing

Check after cutting the Filter.

10 Engine Oil Filter i) Clean ii) Type of Particles : Metal - Steel - Iron - Babit metal - Copper - Rubber

ii) Fuel System

1 Common Rail/ Direct injection

2 Leakages at FIP Shaft seal leak - 'O' ring leak - leak of pipe Check / clean disel tank breather
3 Miss Firing Conduct Morse Test to find faulty Injector
4 Injector Dribbling
5 Timing Problem
6 Filter Good - Clogged - Punctured
7 Fuel Tank Clean - Correded - Damaged
8 Fuel lines Intact - Leakages
9 Sensors Working - Not workng- Missing
10 Injector tip Good - Damaged - Broken- Burnt Cylinder No. :-
11 Cleaning Cleaning of Fuel Tank. (Frequency - Yearly Once) Last cleaning Date :
iii) Air Intake System
1 Air Filter Condition of Filter - OEM - Non OEM - OEM but other model Replacement Interval - Hrs/Kms
2 Filters Clogged Low - Medium - Excess
3 AIR Filter Good - Damaged - puncture - crushed
4 Intake Hose Good - Damaged - Broken (Rubber - Metal)
5 Evacuator Valve (Dust Cap) Avialble - Missing
6 Clamps Tight - Losen - Missing. (Mention exact location of Clamp - )
7 Filter Housing Good - Damaged - Broken
8 Air Pre-cleaner Available - Missing - OEM not fitted
9 Turbo Charger Condition: - Good - Rubbing - Broken - Fins Damaged -/Sharpen
10 Vacuum Indicator Status Working - Not workng- Missing
iv) Cooling System
1 Medium Coolant or Water
2 Radiator Clogged Internal - External - Both Light - Medium - Heavy

3 Radiator Hose (Burst/Leak)
4 Coolant Pump
5 Thermostat
6 Thermostat Functioning
7 Oil Mixing in Coolant
Ok - Burst - Leak - Soften -Harden (if burst check) Check Radiator Pressure Cap Rating -
Last Replacement KMR/HR & Date : KPA/Kgcm2
Check Radiator Pressure Cap Rating -
Ok -Leak- Shaft Broken - Impeller wornout (if leak check) KPA/Kgcm2
Available - Missing
Working - Not working Opening Temperature - C
Condition of Cooler. ( Good - Damaged)

8 Radiator Cap Available - Missing; OEM - Non OEM Check Radiator Pressure Cap Rating -
KPA/Kgcm2

9 Radiator Cap Rating OEM Recommended Rating :- KPA/Kgcm2;

Correct - In Correct
Sl.No Check Point Observation Parameter
10 Radiator Leak Core Puncture/ Core bulging / Core tube soldering area / External object Hit/Burst

11 Radiator Efficiency Check ΔT - Temp difference between Top & Bottom Tank ΔT - C
12 Cleaning Cleaning of Radiator - Internal - External Last cleaning Date :
Check for complete cooling system & Radiator alone separately (To check for any Cooling System Qty (Litrs) -
13 Quantity of coolant internal choking or capacity of tank reduced ) Radiator Qty (Litrs) -
Check Radiator Pressure Cap Rating -
14 Coolant loss Without Leaks KPA/Kgcm2 & Function
15 Coolant Condition Quality Check
16 Temp. Gauge function Working - Not working - Malfunction - Not available
17 Fan Mounting Tight -Loose -Crack- Not available

18 Fan Clutch Working - Not working - Malfunction - Not available.

(Never run with Famaged Fan or wornout leafs )
19 Radiator Mounting Tight -Loose -Crack- Not available

20 Timing Belt condition In tact -Broken - Wornout: Check pulley groove (New belt should protude above Last Replacement KMR/HR & Date :
groove)
v) Electrical System

1 Starter Motor Working - Not Working. Condition of Bentdex - Solinoid;- Working - Not working

2 Alternator Working - Not Working

3 Alternator Belt condition In tact -Broken - Wornout: Check pulley groove
4 Tensioner Check for any failure; Proper function Last Replacement KMR/HR & Date :
5 Sensor's Malfunction
6 Wiring Harness Ok - Chipped off - Broken - Burnt
7 Fuses Correct ratings - Wrong - Jumping with wire
8 Battery Burst ; Rated Battery ; Low Battery ; Dead Check rating :
9 Warnings
10 Fault Codes Display
11 Flywheel Ring condition Good - Damaged
12 Belt condition Ok - Damaged - Missing
13 Engine Control Unit Working - Not Working
(II) Gear Box / Transmission
1 Shifting operation Good - Slipping - Erratic - Particular gear Gear No:
2 Lubrication Level - Grade Of Oil - No oil Grade of Oil & Qty :
3 Metal Particles Mild - Moderate - Heavy
4 Electrical Problem (TECU)
5 Linkages ok - Damaged - Missing
6 Clutch Ok - Slipping - Burnt - Wornout - Broken Last Replacement KMR/HR & Date :
7 Clutch Misuse
8 Clutch Adjustment Good - needs to adjust - needs to replace
9 Master Cylinder Ok - Leak - Not working
10 Flywheel Ok - Wornout - Crack
11 Release Bearing Good - Bad
12 Air Cylinder Good - Leak - Not working
13 Leakages Top Cover - Joint Cover - Oil Seal (Front - Rear)
i) Propeller Shaft
1 U.J Cross Flange Good/Intact - Play - Broken
2 U.J Cross Good - Play - Broken
3 Propeller Shaft Broken Good - Play - Broken
4 Splines Wornout Good - Play - Broken Last Replacement KMR/HR & Date :
5 Bolts Broken Good - Play - Broken
6 Centre Bearing/Mounting Good - Play - Broken
Matching of splines while fitment of Propeller Shaft should be properly taken care while
7 replacing
(III) Differential
1 Seal Good - Leak
2 Pinion Bearing Play Good - Play - Broken ; If play needs to adjust
3 Metal Particles Found - Not found (specify type of component)

4 Oil Level/Lubrication Ok - No oil - Low oil Qty in Litrs :

Recommended Grade by OEM :
5 Bearing Failure Good - Play - Broken - Damaged
6 Metal type of Paste from Drain Pl Mild - Moderate - Heavy check while service
(IV) Hydraulics
Seal leakage - 'O'-ring leakage - Case drain quantity - Suction Hose Leak / Clamp Loose : Case drain quantity :- ___ in lit/min
1 Pump
Pump Resealing Required (compare with OEM value)
2 Cylinders Seal leakage - 'O'-ring leakage - Housing pipe leak - Cylinder crack Check rod strightness - Pitting marks
3 Tank Crack- Dent - Clean condition - Foreign mateiral
4 Control Valve Good - Spools leak - Wetting - Crack
Sl.No Check Point Observation Parameter
5 Strainer condition Good -Bad - Squeezed- Damage - Filled with Foreign material.(Attach Photo)
6 Breather Good - Clog - Missing
7 Hammer Accumulator leakage - Seal leakage - Bush worn out - chisel broken

8 Hydraulic Motor Seal leakage - 'O'-ring leakage Case drain quantity :- ___ in lit/min
(compare with OEM value)
9 Hose Suction Hose - Clamp - Hose Crimpling - Hose Burst (Age/Pressure)
10 Over Heating Temperature - C
11 Internal Leakage specify the component
12 External Leakage specify the component
13 Noise Low - Medium - Heavy
14 Rod Pin Play Low - Medium - Heavy
15 Filter Clogging Low - Medium - Heavy
16 Particles Metal - Rubber items - Sand
17 Broken specify the component
18 Breather Good - Clog - Missing
19 Accumulator Working - Not Working - Bladder Damaged - Nitrogen Gas charging reqd
20 Drifting (PRC) Internal leak - Relief valve malfunction
Rod Bend - Rod Pitting marks (due to age or other) - Cylinder bore damage - Piston
21 Cylinder (PRC) damage - Gland damage - Mounting bolts damage - Eye end wornout - Bush - Bore -
broken

22 Hydraulic Oil No Oil - Incorrect Oil - Low Oil - Excess Oil - contaminated - Foaming Qty in Litrs :
Recommended Grade by OEM :
23 Contamination Mixing with water -Aearation - Color changed - Mixing with other oil
24 Adjustment PRV adjustment
25 Not Taking Load Check cycle time of all Hydraulic Operation Attach Cycle time report
26 Drive Coupling Good - Wornout - Broken
27 Suction Hose Good - Leak - Harden - Aged
28 Condition of return filter Good - Clogged - Damaged- Burnt
29 Cleaning Cleaning of Hydraulic Tank Last cleaning Date :
(V) Final Drive
1 Leakages
2 Sun Gear Failure/Damage Good - Pitting -Wornout - Broken
3 Planetary Gear Damage Good - Pitting -Wornout - Broken
4 Ring Gear Damage Good - Pitting -Wornout - Broken
5 Oil No Oil - Incorrect Oil - Low Oil - Excess Oil - contaminated
6 Metal Particles
7 Leakage from Floating Sealing Good - Leak (Light - Moderate-Heavy)
(VI) Brakes
1 Break Pedal Play/Damage Good - Play - Damaged
2 Leaking Thread Valve Good - Play - Damaged
3 Count of Stroke
4 Position of Neutralizer Switch
5 Camshaft Wornout Good - Wornout
6 Spring Good - Broken - Slip
7 Dust Entry Yes - No
8 Dust Cap condition In Tact - Damaged - Missing
9 Dust Cover condition In Tact - Damaged - Missing
i) Immersed Brake
10 Oil Leakage
11 Float Seal Leakage Good - Leak (Light/Medium/Heavy) Last Replacement KMR/HR & Date :
12 Plates worn out/Play Good - Wornout - Damaged - Burnt - Play Play in mm :-
13 Metal Particles
14 Clutch Material Found - Not found
15 Oil Color Change Good - Blacken - Normal - Thick due to Burning
16 Parking Brake Working - Not working - Damaged - Slip. (Inbuilt - External)
17 Parking Brake Pad Good - Wornout - Damaged
18 Parking Brake Sensor Working - Not working - Damaged
19 Inbuilt Parking Check Electrical function - Hose - Accumulator
20 Cluth pad wornout Readings to be check Wear in mm:-
21 Hose & Accumulator Good - Damaged - Not available
22 Linkages/Cables Good - Wornout - Damaged
23 Shoe & Shoe Pads Good - Wornout - Damaged
24 Brake Drum Good - Wornout - Damaged
ii) APM
1 Air Compressor Condition - Time taken for System Air Pressure Buildup :-
2 APM Filter Filter Condition - Replacement Frequency Last Replacement KMR & Date :
3 Pnuematic System Leakages Check for any leakages in overall pnuematic system & rectify
4 Air Tank Drain Plug to check & remove water on Daily Basis
Sl.No Check Point
(VII) Suspension
1 Leaf Spring (Front)
2 Leaf Spring (Rear 1)
3 Leaf Spring (Rear 2)
4 Leaf Spring (Rear 3)
5 Shock Absorber
(VIII) Chassis
1 Main Chassis
Observation Parameter
[Good - Broken ] [ LHS - RHS ] [Bush: Crack - Wornout ] Mention the No. from Hing Point -
[ Stopper : Available - Wornout - Damaged - Missing]
[Good - Broken ] [ LHS - RHS ] [Bush: Crack - Wornout ] Mention the No. from Hing Point -
[Good - Broken ] [ LHS - RHS ] [Bush: Crack - Wornout ] Mention the No. from Hing Point -
[Good - Broken ] [ LHS - RHS ] [Bush: Crack - Wornout ] Mention the No. from Hing Point -
Measure the height of Spring and compare with New one.
Good - Rust - Corroded - Bend - Cracks -Covered with Concrete - Wornout - Fatigue

2 Cross Members Good - Rust - Corroded - Bend - Cracks -Covered with Concrete - Wornout - Fatigue

3 Others Good - Rust - Corroded - Bend - Cracks -Covered with Concrete - Wornout - Fatigue

4 Wheel Hub Last Wheel Hub Servicing Details - KMR & Date
5 Block Trailers Check pin - Check bush - Check mountings
Check floor condition
Check Door hinges
Check leaf springs - drag links bushes & pins - Equalizer
Check straightness with level thread trepezoidal test (line dori)
(VIII) Cabin With ROPS - Without ROPS
1 Good - Rust - Corroded - Bend - Cracks - Wornout - Fatigue
2 Not in Driving Condition - Interior bad condition - Good
(IX) Attachment
1 Tipper Body Excessive Vibration - Crack - Condition of Floor & Door

2 Bucket Bucket/ frame bores Wornout - Bush & Pin wornout - Tooth Wornout - Tooth Missing

3 Fork Bend - Broken - Wrong Usgae

Filter - Seal leakage - Bush wornout - Chisel wornout or Broken - Accumulator Gas
Last filter replacement -
charging - damage - Thru bolt broken - Piston damage - Rotation of chisel side locks - Last Selas Replacement -
check contact area of Piston & chisel contact areas of Both - Greesing Manual OR Auto
4 Rock Breaker greesing Type of Greese Go for chisel Paste Last Bushes Replacement -

Measurement in mm :
Bush Wear Limit needs to check by GO - NO GO Gauge on Fortnight basis (OEM limit in mm - )
i) Greasing System
1 Auto Lubrication Working - Not working; If working : Grade of Grease - (Insist for Zero grease)
2 Manual Operator - Site - Service Van ; Frequency in hrs ____ in days ____
3 Bucket Grease retaining seal Ok - Damaged - Missing - Leak
(X) Operating Condition
Road Block Top - Graded

Last Scheduled Maintenance Details Date : KMR / HMR Reading :

Last Workshop Inspection Report Date : KMR / HMR Reading :

Last Major Repair Work details Date : KMR / HMR Reading :

Any Operational Complaint by Operator/Driver before or after the failure

Driver / Operator Name : Employee Id : Mobile Number :

Description of Failure :-

Root Cause for Failure :-

Corrective Action to Recommission the Equipment :-

Sl.No Check Point Observation Parameter
Preventive Action to Plug Failure Recurrence :-

Signature & Date : P&E Engineer Cluster Incharge / Region Incharge

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